Apparatus for reproducing threedimensional patterns and the like



March 23, 1943. D. E. HQwARb 2,314,499

APPARATUS FOR REPRODUCING THREE-DIMENSIONAL PATTERNS AND THE LIKE FiledJune' 15, 1941 2 Sheets-Sheet l I l 1 '1 L g1" 20 6 4 fo o 70-m 6'5 6 787619 25 H 71 I I 2.9 I] 74 3 I I 27 o 72 i I d2 March 23, 1943. D. E.HOWARD 2,314,499

APPARATUS FOR REPRODUCING THREE-DIMENSIONAL PATTERNS AND THE LIKE FiledJune 13, l941 2 Sheets-Sheet 2 Patented Mar. 23, l 943 NITED STATESPATENT OFFICE:

APPARATUS FOR REPRODUCING' THREE- DIMENSIONAL PATTERNS AND TH LIKEDarnley'E. Howard, Washingtom-D. C. Application June 13, 1941, SerialNo. 397,984

7 Claims. (01. 90-131) The invention relates to apparatus for repro- Iducing patterns and other articles and objects, and is particularlyuseful in reproducing threedimensional objects. It is applicable to usein die sinking and inthe reproduction of structures such A further aimis to enable the reproduction of an extremely intricate and peculiarlycontoured object with great exactitude bythe exercise of care in themanipulation of the apparatus, and

with great rapidity.

Another importantaim of the invention is to enable the use oforiginalswhich may be readily made by-modeling manually orotherwise in softmaterials if desired, including moist clay, as well 1 A fur--,Additional objects, advantages "and features of invention [reside inthe construction; arrangement, and combination'fof parts involved intheembodiment of the, invention, as will be understood" from the followingdescription and accompanying drawings, wherein; v

Figure 1 is an elevational view of a system embodying the necessaryapparatus for carrying out my invention as to method and mechanism,Figure 2 is a top view thereof Figure-31s a cross sectional viewof thepattern table on the line 3-3 of Figure 1, looking toward the right:'

\ Figure 4 is an enlarged vertical section through the optical system,at right angles to the plane ofFigure 3; I

Figure 5 is adiagram of the system for controlling electrically thevalves by which the fluid level is established onthe pattern table;

Figure 6 is 'a detail 'elevational view .jective lensmounting; o

Figure 7 is a detail of the diaphragm or slide for'fo'rming the image,of the tool, or, in other as patterns made of harder materials,v so thatexpensive metal casts or machined originals in hard materials-are notessential, andthe production of finished work mayb effected from modelsor patterns made by persons unskilled in the operation ofmachinery or inpattern making, casting,

.etc. a f

A further important aim of the invention is to enable the production ofa contour in any given plane of anoriginal piecein-a novel way. A stillfurther important object is. to make it possible for the oper-ator toguide a tool in conformity with such contours without requiring anyrigid or-solid guide to. contact the surface of the pattern.

.Yet another important aim of this invention. is to present a novelcoordination of a work-engaging tool. and an optical system operative inconnection with a pattern contour for the reproduction of a solid having-the* same contour, whether in the same size, or-larger or smaller in adefinite scale relation, with great exactitude. It is also anobject topresent novel apparatus and operative means for effectingthe necessaryrelative movements of a pattern and toolcontrolling means and of the'tool and the work in scaled relatio n, adapted to actual sizereproduction and to largeor small scale reproductions.

words the diameter and shape of a light beam to be projected beside thepattern piece.

Referring more particularly to the drawings,

' there is illustrated a pattern table 10,- supported rotativelyupon anon-rotating screw ,l l, mounted upon a suitable footing l2, which maybe secured upon a floor l3 in any'usual way. Over worm sleeve or nut Hin which the screw l I is l threaded, the nut having a ring gear 15fixed thereon driven by means of a worm l5, mounted ina suitable bracketl'l secured'upon the side of the foot piece I2. The table I0 isrotatable independently upon the screw H by means of a worm l8 mountedupon a bracket I9, fixed on 'thescrew I l, and meshed with a gear 20fixed on the under side of'thetable. v

The table lll'is formed with a basin 2| in which a liquid 22 is,maintained at a variable level independently of the level of the tableand the basin,

this liquid preferable being opaque and of a dis-- tinctive colorcontrasting with the color of the pattern to-be reproduced,'preferablewhite orgray. White. is used where the pattern may be painted black oris of a very dark material, but a. gray may be found preferable Wherethe pattern is white.- 3 I -Set upon the table Ill within the basin 2|,there is a pattern 23 to be reproduced, a formal representaiion of arelief image of a human face being indicated in the present instancealthough various other forms of patterns may be used.

of the ob Means is provided for supplying the liquid 22, which in thepresent instance consists of a reservoir'24 at a higher level than thehighest level to which the liquid is to be raised in the basin withsuitable duct connection 25, leading through the table l and dischargingwithin the basin, the fiow of liquid through this duct being controlledby an electrically operated normally closed valve 26 arranged to open onclosing of the circuit thereto. Also connected to the same duct at itslow part there is a discharge duct 21, having a control valve 28 thereinsimilar to the one 26 except that the effluent outlet of the valve has adischarge or.drain pipe 29, which leads downward to a receiver 30 at aconvenient point or may discharge elsewhere, as preferred.

- For operating the valves 26 and 28, a float 3| is mounted pivotallyupon a suitable fixed support 3201' any suitable kind, the floatoperating a rigid arm 33 fixed with respect to the float and movable atits extremity between two sets of switches each including a movablecontact operable by the arm 33 on movement of the latter in respectivedirections. One' of these switch devices 34. is en a ed in circuit withthe valve 26, while the other switch, 35. is connected in the circuitwith the valve 28. These switches are spring loaded and normally open;being closed by movement of the lever in respective directions from amedial position. Thus. in case of the raising of the table '0 as will besubsequently described. the float 3| will be caused to operate theswitch 35 by action of the arm 33 thereon, causing a decant ng of liquidfrom the basin 2|. so that the liquid is restored to its originalrelation to the switch, at which time the switch 35 will be opened byreturn of the float and arm 33 to its initial or neutral positionclearing both switch On the other hand, when the table I0 devices. islowered. the lowering of the float 3| will close the switch 34, causingopening of the valve 26 by which an accretion of liquid in the bowl iseffected from the supply'in the reservoir 24. raising the level of theliquid 22 to that at which it stood in relation to the float mountingbefore the lowering of the table. The return of the float to' itsneutral position will open the switch and permit closing of the valveagain, which will occur automatically.

An objective lens 36 is mounted on a fixed vertical axis coincident withthe axis of the rotation of the table III by means of an arm 31, fixedon a work table base frame 55 to be described, and a bracket 31 mountedon an elevatable arm 61 ad- .iustable on said frame, as will bedescribed. The lens mounting in the present instance includes an outerbarrel portion 38, fixed upon a telescopic extension 39 of the arm 31,and held in adjusted positions by a set screw 40. Within the barrelthere is.a lens-carrying sleeve 4| vertically slidable in the barrel.and held adjustably on its vertical axis by an adjusting device 42 ofany desired kind, which may include in the present instance the separatesupport bracket 31' and lower rigid bracket arm 43 attached to the arm61 of the work table device, which also serves to support the floatmounting 32. A light beam source 44 is provided above the lens barrel,this being fixed upon a bracket 45, which is secured rigidly upon a,sliding work table base 46 presently to be described, and movable in afixed line toward and away from the table In. The light beam source 44in the present instance may include any approved electric lamp 41,condensers 43 and a photographic image slide 49 removably engaged in thelower part of the lamp mounting.

A rotary work table 50 is provided, mounted revolubly on the work tablebase 46 before referred to, the table being mounted for movement withthe base 46 horizontally and being elevatable with the arm 61 by meansof a screw 5| operable by a worm 52 mounted on a bracket 53 secured uponthe foot 54 of the work table frame 55 having an upper arm 56 of fixedposition carrying a milling head 51, the spindle of which carries thedie sinking cutter or thelike 58. Means is provided for rotating thetable 50, consisting of a gear 59with which a worm 60 is meshed, mountedupon a bracket 6| fixed on the work table base 46. The worm 60 is drivenby a shaft 62 coupled to the shaft of a motor 63 fixed on the table base46, and the worm 60 is also connected by a flexible shaft 64 to the worml6 by which the pattern table in is rotated. The pitches of the worm andsizes of the gears 59 and 20 are so proportioned as to rotate the twotables in synchronism, so that thepattern will be always oriented on ahorizontal axis extending inthe same direction as the correspondingaxis'of the work.

The work table base 46 has a usual dovetail spline '65 engaged slidablyin a carriage 66 mounted slidably upon a lower arm 61 in a dimotion atri ht angles to the direction of movement of the base 46 on thecarriage, The arm 61 is vertically adiustabl upon the frame as at 66, bymeans of the screw 52 and its operating means before described. Thetable base 46 may be 7 moved upon the carria e by means ofa hand screw69 or any-other approved means. and the carriage 66 is movable by meanof a ha d screw 10, both shown in Figure 1. The worm 52 by which thetable 50 is raised and lo ered is nerated b means of a hand c ank a dthis worm and the worm |6 are connected by a flexible shaft 12, so thatoperation of the crank will turn both screws simultaneously. The pitchesof the worms and number of teeth on the gears by which the screws II and5| are tu ned are such that the ratio of elevating movemen of the t blesI 0 and 50 will be the same as the ra o or scale of size of thereproduction desired. The difference in the len th of the incident beam'13 of light from the slide image 14 to the lens and the length of theprojected portion of the beam at 15 from the lens to the surface of theli uid 22 is also in the same proportion: so that if the work is to beproduced one-fifth the size of the original. the distance between theslide and lens is one flfth the distance from the lens to the liquid 22,and

the table 50 is elevated one fifth as much as the table ID on a givenmovement of the crank 1|.

A piece of work 16 is indicated as being fixed on the table 56, inposition to be engaged by the tool 56.

In the practice of my invention, the pattern 23 being suitably set inplace on the table "I, and a piece of material 16 for the work beingflxed on the table 50 in the same relation to the axis of rotation ofthe table 50 as the pattern is to the. ax s of rotation of the table l0.the screw 66 is operated to draw the table and base 46 to one limit ofmovement, or soas to clear the tool from the work. The work beingreduced to a height nearly or quite corresponding to the height of levelin the basin 2| with respect to the pattern when the float is in neutralposition and bothvalves closed. this level being approximately at theapex or highest point of the pattern 23. The crank H is then operated toraise the table l0 and the table 50' softhat the level of liquid-fan clthepattern are raised a distance, and the work alsoelevatedone fifth thedistance. This causes'theliquidlevel to overtake' the'floatwhich waselevated-the; same distance as thework, and causes raising-of the floatandoperation of the valve 28'until lowering of the. liquid returns thefioat to neutral position where the valve again closes and establishes aliquid level in the basin fixedfor the time being. This exposes a partof the pattern and discloses the contour of the base of the exposed partbyits junction with the liquid 22.- The tool 58 isnow at a level toengage the work when the, latter is moved into engagement with the tool.The screw 69 is now operated to move the work toward the tool, but theoperator observes the location of the spot of light .on the surface ofthe liquid caused by the incidence of the beam I5 thereon. By the properproportioning of the image It, the diameter of the light spot willcorrespond to an image of the cross section of thetool 58 enlarged inthe same proportion which the pattern bears to the work to be produced.The operator now moves the base 6 inward while the motor 63is-inconstant operati n, so'that all portions of material on the work areremoved until the edge of the beam approaches or contacts the contourline at the junction of the liquid and pattern. Moving the base 46- alsomoves the, bracket 45 and light source, so that the beam 15 swings in adirection opposite that in which the work is moved, and over a distancefivetimes as great in the assumed ratio or scale of reproduction aboveindicated. The work is moved so as to swing the spot or image intorecessed parts of the contour, and draws the work backward when theconvexities of the contour are approaching the beam under rotation ofthe table ill, the corresponding rotation of the table 50, results inthe tool 58 cutting the work 16 in corresponding form. After one or moreturns of the tables so as to remove all material on the work beyond thefinished contour at a given level attained by. operation of t e crank1|, the screw 69 is operated to draw the work away from the tool 58again, while the crank II is again operated to raise the tables 10 and50 to new levels. This brings the work to where it may again engage thetool outwardly of the contour to be produced, and causes the liquid toagain function with the float and valves so that its level is loweredfurther. aroundthe pattern as before described, producing a new contourto be reproduced on the work in .the man- 'ner already described. Thesesteps are repeated until the complete'reproduction of the pattern iseffected, when the liquid level will be close to or at the base of thepattern.

After operation with a large diameter tool and corresponding slide 49,where there are contours involved having indentationstoo narrow for thespot or image to enter, another tool of smaller diameter and a new slidewith correspondingly smaller image 14 are introduced, and the tooling ofthe work repeated as before beginning at such upper parts as require thesmaller tool work. A final treatment, with a pointed tool may be carriedout.

In this way original works of high value and delicate finish may bereproduced without liability of injury, as well as more rugged piecesduplicated, or reproduced to scale.

Paper drawings of desired contours may be utilized by mounting them atthe levels corresponding to the liquid levels referred to, or the tableI0 maybe disconnected from the elevating.

drive 12 and the table 50 only elevated in the necessary successivedegrees as respective contours on a drawinglaid on thetable ID arefollowed; producing a three dimensional work from flat drawings.

- When it is desired to change the scale 'of reproduction, the height ofthe arm 31 and light source are'cor'respondingly adjusted and inreproducing from patterns the ratio of the drives atlfiand 52 changedsimilarly.

Itwill be understood that the 1iquid22 may includean oil or the like toreduce surface tension, and may also includelaqueous solutions ormixtures adapted to theuses contemplated; Also if desired in certainwork the screw'il and crank H 1 may be coupled for simultaneousoperation in conventional ways. Y w

. While I have disclosed myiinvention in the'best forms which I havethus. far constructed, ,it' will be understood that this is purelyexemplary, and

that further improvements may be found objvious, includin'gvariations inthe-proportions of parts, substitution of materials, and. mechanicalequivalents, arrangement and construction ofparts, allwithout departingfrom the spirit of z the inventiomas more particularly set forth andindicated by the appended claims.

I claim: I g

l. In a machine of the character described, a pattern table, means toestablish a body of liquid thereon, means to vary the level of theliquid; a

pointer device over the table movable universally,

a Work table, a tool mounted thereover, means to move the tool and worktable relatively in a given direction, means to move said pointer andoperative connections between the means to move the work table and toolrelatively and said means to move the pointer, means to move the workmovement of the work table:

3. Means for establishing a contour around a pattern consisting of atable support, means to establish a body of liquid around a pattern onthe support, means to vary the level of said liquid at will,v the meansfor varying the level of I the liquid consisting of a liquid supply. abasin on the support, duct connections between said supply and thebasin, a feed valve therein, a drain duct from said basin, a drain valvetherein, a float adapted to float on the liquid in the basin and havinga mounting independent of the table support and basin, means to move thefloat mounting and table support vertically relatively at will, andoperative connections between said float andsaid valves, for alternativeoperation on respective opposite vertical relative movements.

4. Means for establishing a contour around a pattern consistingof atable support, means to establish a body of liquid around a pattern onthe support, means to vary the level of said liquid at will, the meansfor varying the level of liquid consisting of a liquid supply, a basinon the support, a duct connection between said supply and the basin, afeed valvetherein, a drain duct from said basin, a drain valve therein,a float adapted to float on the liquid in the basin and having amounting independent or the table support and basin, means to move thefloat mounting and table support vertically relatively at will,operative connections between said float and said valves, foralternative operation on respective, opposite vertical relativemovements, said valves being normally closed, electrical means to openthem, an arm movable by said float under variation of liquid levelrelatively, respective electrical circuits for said valves eachincluding a circuit closer operatively associated with said arm andoperable thereby alternately onmovement of the arm in respectivedirections.

5. Means for establishing a contour around a pattern consisting of atable support, means to establish a body of liquid around apattern onthe support, means to vary the level of said liq:

iiid at, will, the means for varying the level 0! liquid consisting of aliquid supply, a basin on the support, duct connections between saidsupply and the basin, a feed valve therein, a drain duct from saidbasin, a drain valve therein, a

float adapted to float on the liquid in the basin and having a mountingindependent of the table support and basin, means to move the floatmounting and table support vertically relatively at will, and operativeconnections between said float and said valves, for alternativeoperation on respective opposite vertical relative movements, a worktable and tool relatively vertically movable, means to move the tableand tool vertically relatively to each other and operative connectionsbetween the last named means and-:said means to establish theliquidlevel. f 6. Means for establishing a contour around a. patternconsisting of a table support, means to establish a body of liquidaround a. pattern on the support, means to vary the level of said liquidat will, the means for varying the liquid level consisting of a liquidsupply, a basin on the support, duct connections between said supplyandthe basin, a feed valve therein, a drain duct from said basin, a drainvalve therein, a float adapted to float onthe liquid in the basin andhaving a mounting independent of the table support and basin, means tomove the float mounting and table support vertically relatively at will,and operative connections between said float and saidvalves, foralternative operation on respec-- tive opposite verticalrelative-movements, a work 20 table, a tool thereover, means tomove thetable and tool relatively and operative connections between the lastnamed means and said mounting of the float.

7. The structure of claim 1 in which said 25 pointer device consists ofa lens over the pattern table, a light beam source over the lens and onebeing horizontally movable with respect to the other, the operativeconnection between the means to' move the work table and tool relatively30 being connected with the movable one of the two elements consistingof lensand light beam source.

DARNLEY E. HOWARD.

